Method for fastening a tool handle to a tool shaft

Abstract

A method for fastening a tool handle to a tool shaft includes the following steps. First, providing a tool shaft comprising an elongated body having a proximal end and a distal end. Next, providing a tool handle comprising a distal end, a proximal end and a socket formed at the distal end. Next, inserting the proximal end of the tool shaft into the socket of the tool handle, and then staking the proximal end of the tool shaft to the tool handle from two opposite directions.

What is claimed is: 
     
         1 . A method for fastening a tool handle to a tool shaft comprising:
 providing a tool shaft comprising an elongated body having a proximal end and a distal end;   providing a tool handle comprising a distal end, a proximal end and a socket formed at the distal end;   inserting the proximal end of the tool shaft into the socket of the tool handle;   staking the proximal end of the tool shaft to the tool handle from two opposite directions.   
     
     
         2 . The method of  claim 1 , wherein the distal end of the tool handle comprises first and second opposite recesses extending from the top and bottom surface of the tool handle, respectively, toward the socket wall and being oriented perpendicular to the socket axis. 
     
     
         3 . The method of  claim 2 , wherein each recess comprises conical side walls and a flat bottom surface and wherein a thin layer of material separates the flat bottom surfaces of the recesses from the socket wall. 
     
     
         4 . The method of  claim 3 , wherein said staking comprises inserting first and second stakes into the first and second opposite recesses, and punching the first and second stakes into the first and second recesses, respectively, thereby forcing the flat bottom surfaces of the recesses toward the socket wall without breaking the thin layer of material, and creating matching indentations in the flat bottom surfaces and the outer surface of the tool shaft, respectively. 
     
     
         5 . The method of  claim 4 , wherein each stake comprises a cylindrical body terminating into a conical end and wherein the conical end comprises a conical base and two flat inclined surfaces terminating into a common narrow front flat surface and wherein the cylindrical body comprises a recess cutout surface extending longitudinally along the stake axis and wherein said recess cutout surface is oriented perpendicular to the common narrow front flat surface. 
     
     
         6 . The method of  claim 4 , wherein the first and second stakes are punched simultaneously into the first and second recesses, respectively. 
     
     
         7 . The method of  claim 1 , wherein the tool handle comprises a cylindrical body with a rounded rear surface and a flat front surface, and wherein the cylindrical body comprises a concave central section and flutes arranged around the perimeters of the proximal and distal ends. 
     
     
         8 . The method of  claim 7 , wherein the distal end of the tool handle comprises a conical outer surface that is angled relative to the outer surface of the cylindrical body. 
     
     
         9 . The method of  claim 1 , wherein said tool shaft terminates in an end effector or tool tip. 
     
     
         10 . A device comprising:
 a tool shaft comprising an elongated body having a proximal end and a distal end;   a tool handle comprising a distal end, a proximal end and a socket formed at the distal end;   wherein the tool handle is fastened to the tool shaft by inserting the proximal end of the tool shaft into the socket of the tool handle and then staking the proximal end of the tool shaft to the tool handle from two opposite directions.   
     
     
         11 . The device of  claim 10 , wherein the distal end of the tool handle comprises first and second opposite recesses extending from the top and bottom surface of the tool handle, respectively, toward the socket wall and being oriented perpendicular to the socket axis. 
     
     
         12 . The device of  claim 11 , wherein each recess comprises conical side walls and a flat bottom surface and wherein a thin layer of material separates the flat bottom surfaces of the recesses from the socket wall. 
     
     
         13 . The device of  claim 12 , wherein said staking comprises inserting first and second stakes into the first and second opposite recesses, and punching the first and second stakes into the first and second recesses, respectively, thereby forcing the flat bottom surfaces of the recesses toward the socket wall without breaking the thin layer of material, and creating matching indentations in the flat bottom surfaces and the outer surface of the tool shaft, respectively. 
     
     
         14 . The device of  claim 13 , wherein each stake comprises a cylindrical body terminating into a conical end and wherein the conical end comprises a conical base and two flat inclined surfaces terminating into a common narrow front flat surface and wherein the cylindrical body comprises a recess cutout surface extending longitudinally along the stake axis and wherein said recess cutout surface is oriented perpendicular to the common narrow front flat surface. 
     
     
         15 . The device of  claim 10 , wherein the tool handle comprises a cylindrical body with a rounded rear surface and a flat front surface, and wherein the cylindrical body comprises a concave central section and flutes arranged around the perimeters of the proximal and distal ends. 
     
     
         16 . The device of  claim 15 , wherein the distal end of the tool handle comprises a conical outer surface that is angled relative to the outer surface of the cylindrical body. 
     
     
         17 . The device of  claim 10 , wherein said tool shaft terminates in an end effector or tool tip.